Ventilated facade system

ABSTRACT

A ventilated facade system includes a support frame fixed to a surface of a wall to be covered; a plurality of covering panels, each having an outer face and an opposite rear face and being fixed to the support frame in a selected arrangement; a plurality of fixing units that fix the panels to the frame and include a first plate-shaped support element having a flat body, which is fixed to the frame and has an outwardly-projecting and shear-resistant first support bracket lip; a second plate-shaped support element having a plate body with one edge folded to form an acute angle to be inserted into a corresponding cavity formed in the rear face, the support element being resistant to tensile stress and having a portion designed to be fixed to the frame; and a third flat element guiding concurrent edges of contiguous panels, which is fixed to the frame.

FIELD OF THE INVENTION

The invention relates to a ventilated facade system, which is generally designed for covering outer perimeter walls of buildings and creating a gap between the latter and the panels that form the ventilated facade system, for protection from thermal stresses and noise pollution.

BACKGROUND OF THE INVENTION

It has been long known that outer walls of buildings may be protected from thermal stresses and noise pollution using a cover that is generally known as a “ventilated facade system.”

This system consists in the provision of one or more counter-walls mounted to the exterior of walls and parallel thereto, and supported by a grid frame, which stands against and is fixed to the surfaces of the walls to be covered.

Typically, the frame has its own transverse thickness and the outer surface of the latter has typically flat panels mounted thereto, and arranged in orderly rows and columns, in such a number as to entirely cover the surfaces of the walls to be covered.

A panel made of an insulating material, whose thickness is smaller than the total thickness of the wall, is usually installed within such thickness, such that an air gap or ventilation chamber is created, to thereby form the ventilated facade system.

The thickness of the frame creates a gap between the panels and the covered surfaces of the building, for circulation of air flows, which act as a thermal and acoustic barrier.

In practice, ventilated facade systems both avoid direct contact between the perimeter walls of buildings and the surrounding environment, thereby protecting the former from excessive cold and heat, and prevent most sound waves from reaching the walls of the building, thereby protecting it from acoustic pollution.

In certain embodiments of these ventilated facade systems, the panels that form the counter-walls are designed to be opened and closed as needed whereas, in other arrangements, the panels are fixedly mounted to the support frame and air flows into and out of the gap through special apertures formed at the base and the top of the covering system.

Typically, the panels that form the outer covering walls are attached to the support frame by means of appropriate fastening hooks, which have the dual purpose of firmly and durably supporting the weight of each panel and of holding the panels firm against the frame.

Furthermore, the hooks shall also allow quick mounting of panels as well quick replacement thereof in case of damage or wear caused by weather.

The hooks that are currently used for fixing and supporting the panels against the frame have a highly sturdy structure and are oversized to prevent any failure that might lead to accidental removal and fall of the panels, which would be a serious hazard for the safety of people passing by near the covered buildings.

Typically, each hook is composed of a plate that has a quadrangular body, with one edge folded to a V shape, i.e. at an acute angle, relative to the body, thereby forming a projecting lip that is designed to be inserted into a corresponding cavity specially formed in the rear of each panel.

The number of hooks and cavities is proportional to the size and weight of each panel, the geometry of the wall to be covered, as well as the value of the external actions that exert stresses on the wall of the building, such as wind pressure, seismic stresses and the like, and the hooks and the cavities are coupled together before mounting each panel to the frame.

The folding angle of the edge of each hook is selected for the V profile of the folded edge to be forced into its respective cavity, whereby the folded edge will be pressed into friction-engagement with the cavity for substantially stable coupling between the hook and the cavity.

Therefore, a panel that is ready for mounting shall have hooks with their respective folded edges coupled with the corresponding cavities and the bodies with flat portions projecting out of the edges of the panel.

These flat portions have holes for receiving screws and bolts allowing the panel to be fixed to the frame.

This prior art suffers from certain drawbacks.

A first drawback is that the structures of the hooks, and typically their flat portions, are almost entirely exposed to the view of those who look at the curtain walls from the outside, and this affects the exterior appearance of the buildings that are covered with ventilated facade systems.

A second drawback is that, due to the oversize of the hooks, the flat portions thereof cannot be overlapped, because this would cause plane misalignment between the panels that form the counter-walls, due to the thickness of the hooks.

Therefore, the positions of the cavities in the rear of the panels shall be established beforehand, to prevent any interference to occur between hooks of contiguous panels.

In other words, the hooks of contiguous panels shall be placed in misaligned positions, to prevent them from overlapping, and this requires the panels to be formed with hook cavities in different positions from one panel to another.

Therefore, each panel shall be specially formed with hook cavities in particular positions, and not with the same arrangement for each panel, which would certainly be a quicker and more cost-effective solution.

A third drawback is that the coupling between the folded edges and the corresponding cavities becomes substantially loose with time and, when wind impinges upon the panels, such loose coupling may generate vibrations in the panels, that might be transferred to the frame and produce a bothering noise, that will be ultimately transferred from the frame to the perimeter wall of the building, thereby not only affecting noise protection, but also creating additional noise.

SUMMARY OF THE INVENTION

One object of the invention is to improve the prior art.

Another object of the invention is to provide a ventilated facade system that can hide from direct view at least most of the structure of the hooks that fix the panels of the counter-walls to the frame.

A further object of the invention is to provide a ventilated facade system in which panels may be provided with hook cavities in identical positions in each panel, which will afford quicker and less expensive fabrication of the panels.

A further object of the invention is to provide a ventilated facade system that affords easy and quick mounting and removal of each panel.

Yet another object of the invention is to provide a ventilated facade system that allows the support hooks to be placed in any desired position, including positions that cause overlapping with other panels, without causing panel misalignment.

In one aspect the invention relates to a ventilated facade system as defined by the features described hereinafter.

Further aspects of the invention are also described herein.

The invention affords the following advantages:

providing a ventilated facade system having an aesthetically valuable aspect, and ensuring effective heat and sound insulation;

providing a ventilated facade system that affords easy and quick mounting of each panel and, as a result, of each counter-wall;

fabricating panels with standard processes, requiring short processing times;

using a limited number of hooks for fixing and supporting the panels against the support frame;

providing a firm and clearance-free coupling between each panel and the support frame.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional characteristics and advantages of the invention will be more apparent from the detailed description of a preferred, non-exclusive embodiment of a ventilated facade system, which is shown as a non-limiting example in the enclosed drawings, in which:

FIG. 1 is a schematic broken view of a series of panels that form a wall of a ventilated facade system of the invention;

FIG. 2 is a broken cross-sectional view of a detail of FIG. 1, as taken along a plane II-II;

FIG. 3 is a broken cross-sectional view of a detail of FIG. 1, as taken along a plane III-III;

FIG. 4 is a broken cross-sectional view of a detail of FIG. 1, as taken along a plane IV-IV;

FIG. 5 is an enlarged perspective view of a first support element according to the invention;

FIG. 6 is an enlarged perspective view of an element for guiding the edges of panels according to the invention;

FIG. 7 is an enlarged perspective view of second plate-like support elements, each designed for its own panel;

FIG. 8 is a cross-sectional side view of the two second elements of FIG. 7, in overlapping relationship;

FIG. 9 is an exemplary Cartesian diagram that can be used for calculating the number of needed plate-like support elements as a function of the volumes of each panel;

FIG. 10 is an enlarged broken view of detail “DT” of FIG. 3;

FIG. 11 is a schematic rear view of a portion of a wall of a ventilated facade system according to the invention;

FIG. 12 is a broken schematic side view of a portion of the wall of FIG. 11;

FIG. 13 is a broken schematic top view of a portion of the wall of FIG. 11.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

Referring to the above mentioned figures, numeral 1 designates each panel that forms a wall of a ventilated facade system according to the invention.

Each panel 1 is fixed to a support frame 2 which is in turn fixed by brackets 23 to a surface 3 of a perimeter wall 4 of a building to be covered.

The panels are mounted to the frame 2 by means of first plate-like support elements 5, second plate-like support elements 6 and third plate-like guide elements 7 for guiding concurrent edges 8 of panels 1.

More in detail, referring to FIG. 5, it can be noted that each first plate-like support element consists of a flat plate-like body 9 having a thickness of a few millimeters, and with one edge 10, i.e. the lower edge in the operating position, forming two first cantilever lips 11 extending from the side 10, perpendicular to the plate-like body 9.

Through holes 12 are also provided in the plate-like body 9, to be engaged by screws, bolts, rivets and the like (not shown because irrelevant to the invention) for fixing each first support element 5 to the frame 2.

Referring to FIG. 6, it can be noted that a third guide element 7 consists of a plate body 13 having substantially the same thickness as the first plate-like support elements 5 and with second cantilever lips 14 formed therein, extending perpendicular to the plate body 13 and aligned to each other in parallel and perpendicular directions “X” and “Y” by twos.

The plate body 13 also has a series of through holes 15 to be engaged by screws, bolts, rivets and the like for fixation thereof to the frame 2.

Referring now to FIGS. 7 and 10, it can be noted that the second plate-like support elements 6 consist of a plate body 16 which is considerably thinner than the first plate-like support elements and the third guide elements, and hence is very thin, having a thickness of the order of a few tenths of a millimeter.

The plate body 16 has one edge 17 folded at an acute angle relative thereto, to form a hook, as viewed laterally.

Such hook is designed to be engaged in a corresponding cavity 18, as shown in greater detail in FIG. 3, which is formed as an undercut by milling the wall of a panel 1 that will be the rear wall in operation, and is referenced 1A.

Apertures 16A are formed in the plate bodies 16 with various orientations, e.g. parallel to the edges, as shown in FIG. 7.

According to the invention, once all the cavities 18 have been coupled with the hook-like folded edges 17, they are filled with fluid fillers 19, such as a polyurethane adhesive, both to maintain firm coupling and to prevent the formation of undesired clearances between the edges 17 and the cavities 18 and any resulting movement therebetween.

It shall be understood that, as shown in FIG. 10, the folding angle of the edges 17 is preferably, but not necessarily, more acute than the angle of undercut of the cavities 18, such that they will be mutually coupled by a slight force fit.

Referring now to FIG. 11, it shall be noted that a safety mesh 20, e.g. made of glass fibers, is bonded to the rear face 1A of each panel 1, and extends between the girders 21 that form the frame 2 without covering the portions of this rear face 1A that contact the girders 21.

For safer and firmer fixation with time, respective layers 22 of adhesive material, e.g. a polyurethane adhesive, are interposed between the girders 21 and the free ends of the rear faces 1A, to reduce or eliminate the panel vibration problems caused by external stresses that might cause the failure of the panel.

The operation is as follows: the second plate-like elements 6 are placed beforehand, on site, on each panel 1, by forcing the folded edges 17 into the respective cavities 18 formed in the rear faces 1A of each panel 1.

Then, doses of polyurethane adhesive (or any other equivalent material) are introduced into each cavity, to form fillers 19 that fix the folded edges 17 of the second plate-like elements 6 to their respective cavities 18.

It should be noted that, in the fixed state, the second plate-like elements 6 have their respective plate bodies 16 protruding out of the perimeter sides of each panel 1, as shown in FIG. 1.

When a panel 1 is completed and the fillers 19 have set, the panel 1 will be mounted to the frame 2 in its expected position and fixed thereto, e.g. by means of screws that extend through the apertures 16A.

It shall be noted that, if two second plate-like elements 6 overlap when mounting the respective panels 1 to the frame 2, their respective through apertures 16A can be overlapped and aligned such that a single through screw may be used, and extend through the corresponding apertures 16A for fixing both.

Both the first plate-like support elements 5 and the third plate-like guide elements 7 are fixed beforehand to the frame 2, such that the former can provide support to the edge that is designed to be the lower edge of each panel 1 when mounted and the latter can ensure proper orientation of the concurrent edges 8 at the vertex thereof during mounting.

More in detail, the panels 1 are supported, both during mounting and in the mounted state, by two cantilever lips 11 which perpendicularly project out of each plate-like body 9, whereas the orientation and the maintenance of proper orientation is obtained by placing the ends of the edges of each panel 1 on a respective second cantilever lip 14, as schematically shown in FIG. 1 and in FIG. 4.

When all the panels 1 have been mounted and fixed to the frame 2, to thereby form the curtain wall that covers the surface 3 of a building, only the front sides of the cantilever lips 11 and the second cantilever lips 14 can be seen from the outside, because the respective plate-like bodies 9, and plate bodies 13 and 16 are hidden to the view by the panels 1 themselves.

It shall be noted that, according to the invention, the number of cavities 18 to be formed on the rear wall 1A of each panel 1 may be calculated between a minimum value and a maximum value, as a function of the surface area and the thickness of the panel.

Referring now to FIG. 9, it shall be noted that the calculation is performed by placing the number of cavities to be formed on the X axis and the volume values of each panel 1 on the Y axis of a Cartesian diagram.

The diagrams will be expressed by a pair of parallel lines “R3” and “R4” having a general equation Y=AX+B a field being defined therebetween to indicate the thickness “S” of a panel 1.

In the example as shown in FIG. 9, which is presented merely by way of illustration, a reference line has been taken as the line “R1”, corresponding to an optimal thickness “S” value of a 37 mm panel.

The two parallel lines “R3” and “R4” define the thickness “S” of a panel therebetween and the intersections “P1” and “P2” define on the y axis the possible panel volume values “V3” and “V4”, i.e. the minimum and maximum plane dimensions, for the panel to have 4 cavities and, as a result, as many second plate-like support elements 6.

Conversely, the skilled person will understand that, assuming a particular volume “Vn” of a panel 1, and hence its plane dimensions and thickness “S”, as defined by the lines “Rn”, the number “N” of cavities 18 may be determined, as exemplarily referenced in the diagram as N4, N6, N8, N10, N12, as well as the number of second plate-like support elements 6 as required for supporting that particular panel 1.

The invention has been found to fulfill the intended objects.

The invention so conceived is susceptible to changes and variants within the inventive concept.

Also, all the details may be replaced by other technical equivalent elements.

In its practical implementation, any material, shape and size may be used as needed, without departure from the scope as defined by the following claims. 

The invention claimed is:
 1. A ventilated facade system comprising: a support frame affixed to a surface of a wall to be covered; a plurality of covering panels, each of which has an outer face and an opposing rear face and is fixed to the support frame according to a selected arrangement; and a plurality of fixing units of said panels to said frame, wherein said fixing units comprise: at least one first laminar support element having a plate-shaped body fixed on said frame and shaping at least a first support bracket lip that projects toward an outside and is shear-resistant; at least a second laminar support element having a plate-shaped body and one folded edge, said edge being folded according to an acute angle and adapted to be inserted into a correspondent cavity obtained in said rear face, said second laminar support element being pull-resistant and having a portion designed to be fixed on said frame; and at least one third flat guide-maintenance element of concurrent vertexes of contiguous panels, fixed on said frame.
 2. The system as claimed in claim 1, wherein said at least first support element, second support element, and third guide-maintenance element are fitted on said frame according to a selectable number and gaps by a calculation system.
 3. The system as claimed in claim 2, wherein said calculation system comprises a function equation Y=f(X).
 4. The system as claimed in claim 3, wherein said function equation f(X) is (ax+b) or (ax−b).
 5. The system as claimed in claim 1, wherein said at least first support element has a transversal L-shaped cross-section.
 6. The system as claimed in claim 1, wherein said at least second support element comprises passage openings for fixing members to said frame, which can be superimposed to and conjugated in a correspondent way with passage openings of an additional second support element in a superimposed configuration.
 7. The system as claimed in claim 1, wherein an anti-vibration element is interposed between said folded edge and said cavity.
 8. The system as claimed in claim 7, wherein said anti-vibration element comprises a filling of a polyurethane adhesive.
 9. The system as claimed in claim 1, wherein said at least one third guide-maintenance element comprises a flat body, from which couples of second support bracket lips extend that are reciprocally aligned along aligning directions.
 10. The system as claimed in claim 9, wherein said aligning directions are reciprocally perpendicular.
 11. The system as claimed in claim 1, wherein said covering panels are equipped with a net fixed on said rear face.
 12. The system as claimed in claim 1, wherein said fixing units further comprise adhesive elements fitted between said frame and said rear face. 